The incident has led to a number of major safety recommendations.

A worker on a Queensland mine was seriously injured when a 14mm synthetic fibre rope broke during installation of a new conveyor belt.

The worker was struck in the face from the whiplashing rope, resulting in surgery to remove one of his eyes.

Queensland’s deputy chief inspector, mineral mines and quarries Trevor Brown highlighted several key safety recommendations stemming from the incident,  during which a loader was being used to replace an old conveyor belt at a crushing and screening plant.

Three key issues characterised the incident:

Several major recommendations came form the incident:

The most critical control in this instance is separation from the hazard. An exclusion zone should be implemented when using cable, ropes, or similar types of haulage equipment under tension. The exclusion zone should account for any rope or cable stretch under load, plus a significant allowance as a margin of safety, particularly when using synthetic fibre ropes. The exclusion zone must be clearly defined and, where possible, physically prevent entry into the exclusion zone.

Preference should be given to purpose-built equipment such as winches, winders and reelers when installing or replacing conveyor belts. This type of equipment allows for a more controlled belt pull on process and can be operated by personnel at a safe distance. Winches may be fitted with load cells to ensure wire cable breaking strain is not exceeded.

Some traditional synthetic fibre ropes such as nylon and polypropylene are particularly prone to whiplash or failure due to their elasticity. Newer synthetics such as HMPE (high modulus polyethylene) and natural fibre ropes can mitigate this problem. Natural fibre ropes are more prone to degradation and ropes should be checked and replaced on a regular basis.

Belt pull calculations should be carried out prior to a belt installation to determine the correct rated capacity of haulage equipment. Wireless load cells are now available to ensure breaking strain of haulage equipment is not exceeded while workers remain safely outside of the exclusion zone. Load cells can also help detect an abnormal condition during belt haulage activities, prompting an inspection of jam and wedge points.

Winch line dampeners are effective at reducing rope lash on failure, provided they are used as per manufacturer’s instructions.

Safe work instructions related to conveyor installation or replacement should be reviewed to ensure the risk of catastrophic equipment failure is identified and appropriate controls are in place.

As a last line of defence, eye protection should be worn when carrying out tasks where there is a risk from flying material or objects.

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